eaton 9x55 8-15 kva battery upgrade instructions...4 9x558–15kvabatteryupgrade(8–15kva) —rev1...

p/n:Revision 1

9x55 8–15 kVA Battery Upgrade

For use with the Eaton® 9155 and 9355 (8–15 kVA)

Powerware Series

Eaton reserves the right to change specifications without prior notice. Eaton is a registered trademark of Eaton. All other trademarks areproperty of their respective companies.

©Copyright 2017 Eaton, Raleigh, NC, USA. All rights reserved. No part of this document may be reproduced in any way without theexpress written approval of Eaton.

IMPORTANT SAFETY INSTRUCTIONS SAVE THESE INSTRUCTIONS

This manual contains important instructions that you should follow during installation and maintenanceof the UPS and batteries. Please read all instructions before operating the equipment and save thismanual for future reference.

CONSIGNES DE SÉCURITÉ IMPORTANTES — CONSERVER CES INSTRUCTIONS

Ce manuel comporte des instructions importantes que vous êtes invité à suivre lors de touteprocédure d'installation et de maintenance de la PDU. Veuillez consulter entièrement ces instructionsavant de faire fonctionner l'équipement et conserver ce manuel afin de pouvoir vous y reporterultérieurement.

9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1 iii

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iv 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1

Table of Contents

9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1 1

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Eaton has designed a new harness (see Figure 16) for the battery trays within the 9X55 8-15KVA products as aneffort to provide arc flash mitigation. Battery trays should be replaced to include the adapter on every batteryshelf. This adapter is included in models starting in September 2016. Older models require this batteryupgrade.

Prior to the upgrade, the two battery trays in a shelf are oriented in opposite directions. The positive terminal ofthe left tray is to the front of the unit while the negative terminal of the right tray is in the front. After thisupgrade, all trays will be oriented with the positive terminals to the front.

Installing the new adapter requires that you cut the existing terminals off of the red and black wires on the frontof the battery shelf, strip the wire back 1/4 inch, install and crimp the new adapter onto the wires, and addshrink wrap over the crimped terminal.

2 9x55 8–15 kVA Battery Upgrade (8–15 kVA) —Rev 1

Introduction


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WARNING

This procedure involves interacting with components that may be energized.

Any and all work can involve hazards when working on electrical equipment. The work must be done inaccordance with all applicable local, federal, or other safety requirements and must be performed by qualifiedpersonnel.

! IMPORTANTIn the event of input power failure while performing this procedure, battery backup will not be available.

1. If possible, remove power from the system. Otherwise, follow the instructions in the UPS Maintenancesection of the User’s Guide to place the 9x55 8-15kVA UPS in Maintenance bypass. First, put the UPS intobypass then move the switch to maintenance bypass. However, if the UPS cannot be placed inmaintenance bypass, the upgrade can still be performed by removing power from the system.

Figure 1. Bypass Mode (UPS mounted Maintenance Bypass Switch located at the rear of the unit)


2. Verify that the UPS battery circuit breaker CB1, at the rear of the unit, is open. Follow applicable lockout/tagout procedures.

Figure 2. CB1 Is Open (Located at the rear of the unit)

NOTE If an external battery cabinet is attached, it must be disconnected from the UPS. Ensurethat CB1 is open on each associated external battery cabinet.

Battery Upgrade Procedure


3. Remove the front dress panel of the battery compartment.

Figure 3. Remove Front Panel



4. Using a 7mm nut driver, remove the screws that secure the battery dead front and remove the dead front.

Figure 4. Remove Battery Dead Front Screws

Figure 5. Battery Dead Front Removed



5. Disconnect all the cabinet harnesses from all the battery trays, starting with all the positive (red) wires thenall the negative (black) wires. Ensure that the wires do not come into contact with any metal framing. It isrecommended to isolate the connectors by using a non-conductive electrical tape to secure the end ofeach connector.

Figure 6. Disconnect the Cabinet Harnesses



Figure 7. Disconnected Cabinet Harnesses

WARNINGAll battery trays must be disconnected prior to proceeding any further.



6. Using a voltmeter, measure the voltage between the positive (+) and negative (-) disconnected harnessfrom each shelf/string to verify that there is no voltage.

Figure 8. Verify Zero Voltage

WARNINGAfter performing Step 6, there will still be full battery string voltage between the positive (red) and negative(black) terminals of the battery trays.



7. Slide one battery tray half way out and disengage the tray to tray jumper from the tray clips.

Figure 9. Disconnect Tray to Tray Jumper From Tray Clips

8. Disconnect the tray to tray jumper (white terminal on a black wire).

Figure 10. Disconnected Tray to Tray Jumper



9. Slide both battery trays completely out of the unit.

Figure 11. Both Trays Slid Completely Out



10. Remove and discard the tray to tray jumper.

Figure 12. Discard Tray to Tray Jumper

11. Repeat Steps 7–10 for the other battery shelves until all battery trays have been removed from the unit.

Figure 13. Empty Unit



12. Slide the new battery trays into the unit. The positive (+) terminal of each tray should face the front of theunit and be on the right side of the tray (highlighted in yellow in Figure 14). When sliding it into position, liftthe rear of each battery tray onto the shelf to get it started.

Figure 14. Insert New Battery Trays

13. Locate the remaining cabinet wiring that was previously disconnected from the old trays. Use a wire cutter(preferably the scissor action type as opposed to diagonal cutters) to cut/remove the existing femaleFaston® terminal on the cabinet harness (spade terminal off the ends of the red and black wires). It ispreferred to perform this step by doing one string/shelf at a time.



14. Use a wire stripper (preferably the no-nick type so that no wire strands are cut off or nicked/weakened) tostrip 1/4 inch of insulation from each of the red and black wires.

Figure 15. Strip 1/4 Inch of Insulation



15. Connect the newly provided adapter harness (see Figure 16) to the UPS battery tray wiring, using thecrimp tool (or equivalent) illustrated in Figure 17. It is recommended that crimp tool PN 59824-1 orequivalent is used in this step. Ensure that the two pieces of black heat shrink (highlighted in yellow inFigure 18) are on the adapter assembly. Then insert the negative (black) wire into the crimp terminal on theblack wire of the retrofit adapter (see Figure 18).

Figure 16. New Adapter

Figure 17. Recommended Crimp Tool

WARNINGEnsure that no bare wire is exposed outside of the crimp terminal.


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Figure 18. Add New Adapter Harness to the Battery Cabinet Wires

16. Repeat the insertion and crimping steps for the positive (red wire), ensuring that no bare wires are hangingout of the crimp.

Figure 19. Inserting and Crimping the Red Wire to The Adapter Harness



17. Slide the black heat shrink tubing over each crimp terminal, one at a time. Either heat the heat shrink to getit to contract around the connections or use tie wraps to hold it in place (pull tightly, then cut the excesslength).

Figure 20. Place and Secure Heat Shrink Tubing

18. Carefully push the newly modified wiring set back into the unit between the newly installed trays.

Figure 21. Push Wires Between Newly Installed Trays

19. Repeat Steps 15–18 for all battery shelves.

20. Verify the correct polarity between the newly installed UPS harness adapter and the battery tray harnessprior to making each connection.

CAUTIONAll the battery shelves must be modified to incorporate the new adaptor harness (illustrated in Figure 16) priorto connecting any battery trays. Mating the battery connectors on one shelf would make all of the other shelfwires electrically live.



Figure 22. Connecting the Anderson Connectors (black to black and red to red)

21. Push the new harness and connections back against the battery cases. Secure the right side harness tothe battery tray using a single tie-wrap to prevent the connections from coming into contact with the deadfront and its screws when reinstalled.



22. Reinstall the dead front and secure with the previously removed 7 mm screws. Ensure that the trayretainer clips (on the back of the dead front) do not pinch the battery cables.

Figure 23. Reinstall the Dead Front

Figure 24. Reinstalled Dead Front

23. If an external battery cabinet is attached, reconnect it to the UPS.



24. Reinstall the front dress panel.

Figure 25. Battery Cabinet Front Dress Panel Reinstalled

25. Follow the instructions in the equipment’s User’s Guide (shown in the “Normal Mode Startup” section) tocommand the unit to normal mode of operation.



NOTE The figure below provides a schematic example of the end result as a reference for atwo-string / two-shelf configuration:

Figure 26. Schematic Example of New Configuration


eaton 9x55 8-15 kva battery upgrade instructions...4 9x558–15kvabatteryupgrade(8–15kva) —rev1...

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